Non stain flooring

ABSTRACT

A flooring material ( 1 ) comprises a base portion ( 2 ) having a coating portion ( 3 ) which imparts improved stain resistance to the flooring material ( 1 ) and is positioned in contact with an upper surface of the base portion ( 2 ). The coating portion ( 3 ) creates an upper surface of the flooring material ( 1 ). A particulate material ( 6 ) is embedded in the coating material ( 3 ) and at least partially penetrates the base portion ( 2 ). The particulate material ( 6 ) provides a roughened effect to the upper surface of the flooring material ( 1 ) and protects the coating from wear. The coating ( 3 ) merges into the base portion ( 2 ) where they meet at joint ( 4 ) to form a stratified portion ( 5 ).

The present invention relates to the treatment of flooring to improvestain resistance and in particular to flooring with enhanced slipresistance and especially PVC flooring with enhanced slip resistancetreated to improve stain resistance and to a method of impartingimproved stain resistance to flooring, particularly PVC flooring withenhanced slip resistance.

To provide enhanced slip resistance flooring is generally manufacturedhaving a roughened surface which can be created by embossing the surfaceor by the addition of particulate material to the main component of theflooring during manufacture.

The roughened surface of the flooring increases the risk of dirt beingtrapped on the surface. The dirt, depending on its nature, can becompatible with components of the flooring resulting in absorption ofthe dirt into the surface giving rise to a stain.

It is known to apply a coating to a cured floor with enhanced slipresistance to impart increased stain resistance. However, theapplication of such a coating generally reduces any surface roughnessand thus decreases the slip resistance of the floor.

A particulate material can be sprinkled on top of the coating applied tothe cured flooring to impart slip resistance. However the coatingapplied generally thin and adhesion of the particulate material is thusreduced. Such floorings generally lose their non-slip properties quicklyas the particulate material becomes dislodged from the coating.

The present invention provides a flooring material comprising a baseportion, a coating portion, imparting improved stain resistance to theflooring material, being positioned in contact with an upper surface ofthe base portion and creating an upper surface of the flooring materialand a first particulate material embedded in the coating portion and atleast partially penetrating the base portion to provide a rougheningeffect of the upper surface of the flooring material for enhanced slipresistance and resistance to wear.

We are therefore able to provide a flooring with enhanced slipresistance having improved stain resistance without affecting theeffectiveness as the life of non-slip properties which are achieved bythe particulate material.

Preferably the flooring material is a plastics flooring material, forexample, PVC, modified olefin/olefin copolymer, plasticised acrylic,polyester.

Preferably, the base portion comprises a plastics material such as a PVCplastisol material. The base portion may include a further particulatematerial dispersed therein. The further particulate material may bealuminium oxide or any other suitable grit. The base portion may containa pigment. The base portion may include one or more reinforcingsupports, the supports are preferably glass fibre reinforced non-wovensupports.

The base portion may be made up of one or more layers of plasticsmaterial, preferably up to three layers are envisaged.

The coating portion of the flooring material of the present inventionprovides improved stain resistance to the flooring material.

It is believed that the coating creates a barrier between the uppersurface of the flooring material and the base portion thus preventingexposure of the base portion to possible stainants. The coating mayfurther prevent migration of components of the base portion to the uppersurface of the flooring material where contact with possible stainantscould occur.

The first particulate material being embedded in the coating portion andpenetrating the base portion means that the coating portion does notdestroy the non-slip properties of the flooring material and the firstparticulate material is less likely to become dislodged thus prolongingthe life of the non-slip properties of the flooring material.

The first particulate material is known as grit can be any one or moreof a number of types of hard particles including silicon carbide,silicas (quartz or coloured/natural sands or flints), aluminium oxideand emery.

The use of a further particulate material throughout the base portionfurther prolongs the non-slip properties of the flooring material duringwear.

The base portion of the flooring material may further contain pigmentedPVC chips, quartz chips or other decorative additives to add adecorative effect to the flooring material.

The coating portion preferably merges into the base portion to someextent where the portions meet providing an amount of the coatingportion in the base portion, this amount of coating portion preferablydecreases as the distance from the meeting of the base portion and thecoating portion increases.

The merging of the coating portion into the base portion provides someimproved stain resistance in the base portion even after the coatingportion has been worn away.

The coating portion may comprise any conveniently availablethermoplastic material or, alternatively, thermoset material.

The present invention further provides a method of making a flooringmaterial comprising a base portion, a coating portion imparting improvedstain resistance to the flooring material and positioned on an uppersurface of the base portion and forming an upper surface of the flooringmaterial and a first particulate material embedded in the coatingportion and at least partially penetrating the base portion to provide aroughening effect to the upper surface of the flooring material forenhanced slip resistance and protection from wear, the method comprisingthe steps of:

a) mixing together the components of the base portion;

b) spreading the mixed components of the base portion on a surface;

c) carrying out at least one application of components of the coatingportion in powder form to the components of the base portion;

d) carrying out at least one application of a first particulate materialto the components of the base portion before or after applying thecomponents of the coating portion in powder form;

e) heating the powder coated base portion to cause the powder coating toform a film.

Preferably the components of the base portion form a paste when mixed.

The paste is preferably spread on the surface at a controlled thickness,preferably a blade is used to spread the paste at a controlledthickness.

When the powder coated paste is heated the powder coating preferablymelts and flows to form the film.

If the powder coating is a thermoplastic material the application ofheat in step e) simply melts the coating and allows it to flow and forma film.

If the powder coating is a thermosetting material the application ofheat in step e) cures the thermosetting material.

The application of heat in step e) may also serve to gel and cure thebase portion where the base portion comprises a PVC plastisol material.

Preferably the components of the coating portion are applied to thepaste while it is wet. Alternatively the components of the coatingportion may be applied to the base portion after it has been cured.

Applying the components of the coating portion as a powder to a wetpaste is advantageous as the components of the coating portion can blendinto the wet paste to some extent so that some of the components of thecoating portion are present in the wet paste, and therefore the baseportion of the flooring material, in decreasing amounts as the distancefrom the surface of the paste, is increased. The effect is a stratifiedcoating which imparts improved stain resistance even when the coatingportion has become worn.

However the components of the coating portion can be applied to the baseportion after it has been cured. In this case the components of thecoating will not blend with the base portion to give a stratified effectbut the advantages of the coating present on the surface of the baseportion will still be achieved.

Some of the coating portion in powder form can be mixed with thecomponents of the base portion.

The application of the first particulate material to the powder coatedwet paste allows the particulate material to be pressed by embossingthrough the coating into the paste. This is difficult if the baseportion has been cured before coating, but it is possible if the baseportion has not set completely.

The application of the first particulate material after the componentsof the coating portion in powder form will reduce the rate of sinkage ofthe particulate material into the wet paste thus allowing reproducibledeposition of first particulate material by mass per unit area.

The components of the base portion preferably comprise a plasticsmaterial such as a PVC plastisol. A further particulate material such asaluminium oxide may be included as a component of the base portion. ThePVC plastisol may contain a pigment. The base portion may comprise oneor more layers of a plastics material.

A dressing of, for example, silicon carbide may be added to the pastespread at a controlled thickness to confer further slip and wearresistance and give some aesthetic properties. A variety of particles orchips such as PVC chip particles or coloured quartz particles may beadded to the paste spread at controlled thickness by, for example,sprinkling the particles from above.

The powder coated paste is heated, most preferably in an oven, to meltthe powder coating.

The product is preferably cured for 1-10 minutes, most preferably 3minutes, at 150-220° C., most preferably 190° C.

Preferably the product is embossed. Embossing preferably takes placewhile the product is still hot and soft after curing and involves theapplication of pressure preferably by means of a roller.

The components of the coating portion in powder form may be applied by asprinkle system, a roller pick-up/brush off type system or a spraysystem.

More than one application of the components of the coating portion inpowder form may be necessary.

More than one application of the first particulate material is possible.

The presence of the coating portion is likely to reduce water absorptionof the flooring material of the present invention. The presence of thecoating portion also reduces the amount of volatile organic compoundsgiven off.

The present invention will now be described by means of example onlywith reference to the drawings in which:

FIG. 1 shows a cross sectional view of a flooring material of thepresent invention.

FIG. 1 shows a cross section of a portion of flooring material 1 havinga base portion 2 and a coating portion 3 wherein the coating portion 3merges into the base portion 2 where they meet 4 to form a statifiedportion 5.

The grit like particulates 6 are embedded in the coating portion 3 andpenetrate the base portion 2.

The following examples are illustrative of the present invention:

a plastisol paste typically comprising:

Phr (parts per hundred of resin) PVC powder 100 Plasticiser 30-70Mineral filler  0-100 Thermal stabiliser 1-3 Pigment 1-6

 is produced in a known way. Other additives such as rheology modifiers,biocides, uv stabilisers etc. may also be used. Grits of the appropriateparticle size are added at the required level. The paste produced maythen be treated in a variety of ways some of which are covered by thefollowing examples:

EXAMPLE 1

Powder is blended with the paste at an addition level of 1% (w/w) andthe paste is spread coated at 2 mm by knife over bed on to a non-wovensupport. Powder is then applied to the surface at the requiredapplication rate (50 gm⁻²). Particles of silicon carbide and colouredquartz are each scattered on the surface at the rate of 100 gm⁻². Thepaste is then gelled for 3 minutes at 160° C. Further powder at the rateof 50 gm⁻² is applied and further silicon carbide is applied at the rateof 100 gm⁻². The product is then fused at 190° C. for 3 minutes andembossed.

In this example the powder is included in and on the surface of the wetpaste and a stratified effect is achieved as the powder coating mergeswith the paste.

EXAMPLE 2

Powder is blended with the paste at an addition level of 1% (w/w). Thepaste is spread coated at a thickness of 2 mm by knife over roller overbed on to a non-woven support. Particles of silicon carbide and colouredquartz are each scattered on the surface at the rate of 100 gm⁻². Thepaste is then gelled for 3 minutes at 170° C. Powder at the rate of 50gm⁻² is applied and further silicon carbide is applied at the rate of100 gm⁻². The product is then fused at 190° C. for 3 minutes andembossed.

In example 2 the powder is applied over a cured PVC base layer havingquartz and silicon carbide and further powder therein prior toapplication of further silicon carbide. Stratification of the powderthroughout the product will not occur due to the powder being applied tothe cured base layer.

EXAMPLE 3

Powder is blended with the paste at an addition level of 1% (w/w). Thepaste is spread coated at a thickness of 2 mm by knife over bed on to anon-woven support. The paste is then gelled for 3 minutes at 160° C.Powder at the rate of 50 gm⁻² is applied and particles of siliconcarbide are applied at the rate of 100 gm⁻². The product is then fusedat 190° C. for 3 minutes and embossed.

In example 3 the powder is applied over a cured PVC base layer having nogrits therein prior to application of silicon carbide. Stratificationwill not be achieved for the reasons set out in Example 2.

EXAMPLE 4

Powder is blended with the paste at an addition level of 1% (w/w) Thepaste is spread coated at 2 mm by knife over roller on to a non-wovensupport. Particles of silicon carbide and coloured quartz are eachscattered on the surface at the rate of 100 gm⁻². The paste is thengelled for 3 minutes at 160° C. Powder is applied at the rate of 50gm⁻². The product is then fused at 200° C. for 2 minutes and embossed.

In example 4 the powder is applied over a cured PVC base layer havingsilicon carbide and quartz therein. Again stratification will not beachieved.

EXAMPLE 5

The paste is spread coated at 2 mm by knife over roller on to anon-woven support. Powder is applied at the rate of 50 gm⁻². Particlesof silicon carbide and coloured quartz are each scattered on the surfaceat a rate of 100 gm⁻². The product is then fused at 200° C. for 2minutes and embossed.

In example 5 the powder is applied to a wet PVC paste prior to theapplication of silicon carbide and quartz and stratification of thepowder throughout the product and is likely to occur.

What is claimed is:
 1. A flooring material comprising a base portion, acoating portion imparting improved stain resistance to the flooringmaterial being positioned in contact with an upper surface of the baseportion and creating an upper surface of the flooring material, and afirst particulate material embedded in the coating portion and at leastpartially penetrating the base portion to provide a roughening effect ofthe upper surface of the flooring material for enhanced slip resistanceand protection from wear.
 2. A flooring material according to claim 1wherein the flooring material is a plastics flooring material.
 3. Aflooring material according to claim 2 wherein the plastics flooringmaterial is PVC, a modified olefin/olefin copolymer or a plasticisedacrylic or polyester polymer.
 4. A flooring material according to claim1 wherein the base portion comprises a PVC plastisol material.
 5. Aflooring material according to claim 1 wherein the base portion includesa further particulate material dispersed therein.
 6. A flooring materialaccording to claim 5 wherein the further particulate material isaluminium oxide.
 7. A flooring material according to claim 1 wherein thebase portion contains a pigment.
 8. A flooring material according toclaim 1 wherein the base portion includes one or more reinforcingsupports.
 9. A flooring material according to claim 8 wherein thesupports are glass fibre reinforced non-woven supports.
 10. A flooringmaterial according to claim 1 wherein the base portion is made up of oneor more layers of plastics material.
 11. A flooring material accordingto claim 10 wherein the base portion comprises up to three layers ofplastics materials.
 12. A flooring material according to claim 11wherein the first particulate material is any one or more of a number oftypes of hard particles.
 13. A flooring material according to claim 11wherein the base portion of the flooring material contains pigmented PVCchips, quartz chips or other decorative additives to add a decorativeeffect to the flooring material.
 14. A flooring material according toclaim 11 wherein the coating portion merges into the base portion wherethe portions meet providing an amount of the coating portion in the baseportion.
 15. A flooring material according to claim 14 wherein theamount of coating portion merged into the base portion decreases as thedistance from the meeting of the base portion and the coating portionincreases.
 16. A flooring material according to claim 1 wherein thecoating portion comprises any conveniently available thermoplasticmaterial or thermoset material.
 17. A method of making a flooringmaterial comprising a base portion, a coating portion imparting improvedstain resistance to the flooring material and positioned on an uppersurface of the base portion to form an upper surface of the flooringmaterial and first particulate material embedded in the coating portionand at least partially penetrating the base portion to provide aroughening effect to the upper surface of the flooring material forenhanced slip resistance and protection from wear, the method comprisingthe steps of: a) mixing together the components of the base portion; b)spreading the mixed components of the base portion on a surface; c)applying at least one first dressing of components of the coatingportion in powder form to the components of the base portion to at leastpartially penetrate the base portion; d) applying at least one dressingof a first particulate material to the components of the coating portionin powder form; e) heating the base portion and said at least one firstdressing to cause the components of the coating portion in powder formto form a film.
 18. A method according to claim 17 wherein thecomponents of the base portion form a paste when mixed.
 19. A methodaccording to claim 18 wherein the paste is spread on the surface at acontrolled thickness.
 20. A method according to claim 19 wherein a bladeis used to spread the paste at a controlled thickness.
 21. A methodaccording to claim 17 wherein when the base portion is heated thecomponents of the coating portion in powder form melt and flow to formthe film.
 22. A method according to claim 17 wherein the components ofthe coating portion are applied to the paste while it is wet.
 23. Amethod according to claim 17 further comprising gelling or curing thebase portion before applying the components of the coating portion. 24.A method according to claim 17 wherein some of the coating portion inpowder form is mixed with the components of the base portion.
 25. Amethod according to claim 17 wherein a dressing of silicon carbide,silicas, aluminium oxide, emery or flint is added to the paste spread ata controlled thickness to confer further slip and wear resistance andgive some aesthetic properties.
 26. A method according to claim 17wherein the product is cured for 1-10 minutes at 150-220° C.
 27. Amethod according to claim 17 wherein the flooring material is embossed.28. A method according to claim 17 wherein the components of the coatingportion in powder form are applied by a sprinkle system, a rollerpick-up/brush off type system or a spray system.
 29. A method accordingto claim 17 wherein more than one application of the components of thecoating portion in powder form takes place.
 30. A method according toclaim 17 wherein more than one application of the first particulatematerial takes place.
 31. A floor covering material comprising a PVClayer and having aggregate embedded in the material for providingsurface roughness wherein the material incorporates a barrier layer ofpolymeric material other than PVC fused into the upper surface of thePVC layer, the aggregate being exposed at the surface of the barrierlayer.
 32. A material according to claim 31 wherein the barrier layer isof a cured polymeric material.
 33. A material according to claim 31wherein the barrier layer is of a thermoplastic material.
 34. A materialaccording to claim 31 wherein the barrier layer is at least as flexibleas the underlying PVC layer.
 35. A material according to claim 31wherein the barrier layer is transparent or translucent.
 36. A materialaccording to claim 31 wherein the polmeric material of the barrier layerprovides enhanced dirt release and/or stain resistance in comparison tothe PVC.
 37. A material according to claim 31 wherein the barrier layercomprises a polyolefin, (co-)polyester, (co-)polyamide, polyurethane,phenol formaldehyde, epoxy or acrylic polymer or a mixture thereof. 38.A material according to claim 31 wherein the floor covering material hasan embossed surface.
 39. A material according to claim 31 wherein theaggregate is quartz, corundum, and/or silicon carbide.
 40. A method ofproducing a floor covering material comprising (a) spreading a PVCplastisol on a substrate, (b) distributing over the surface of theplastisol a powder of a film forming, heat fusible polymeric materialother than PVC and a particulate aggregate material, and (c) effectingheating to fuse the plastisol and convert the powder into a film, steps(b) and (c) being effected such that aggregate is exposed at the surfaceof the film.
 41. A method according to claim 40 wherein the powder isdistributed over the plastisol prior to the aggregate material.
 42. Amethod according to claim 41 wherein the powder applied to the plastisolis softened prior to distribution of the aggregate.
 43. A methodaccording to claim 40 wherein the powder is distributed over theplastisol simultaneously with the aggregate.
 44. A method according toclaim 40 wherein the aggregate is distributed over the plastisol priorto the powder.
 45. A method according to claim 44 wherein excess powderis removed from the plastisol prior to step (c).
 46. A method accordingto claim 45 wherein excess powder is removed by suction.
 47. A methodaccording to claim 40 wherein the powder is a thermoplastic material.48. A method according to claim 40 wherein the powder is of a curableresin system.
 49. A method according to claim 48 wherein said resinsystem is cured by heat and curing is effected in step (c).
 50. A methodaccording to claim 48 wherein the resin system is curable byUV-radiation.
 51. A method according to claim 50 wherein UV curing iseffected subsequent to step (c).
 52. A method according to claim 50wherein the powder comprises a polyolefin, (co-)polyester,(co-)polyamide, polyurethane, phenol formaldehyde, epoxy or acrylicpolymer or a mixture thereof.
 53. A method according to claim 50 whereinembossing is applied subsequent to step (c).
 54. A method according toclaim 50 wherein the aggregate is quartz, corundum and/or siliconcarbide.
 55. A method according to claim 50 wherein the powderincorporates at least one of a flow modifying agent, a flame retardant,a biocide, a gloss modifier and a matting agent.
 56. A flooring materialas specified in claim 12 wherein the hard particles include particles ofa material selected from the group comprising silicon carbide, silica,aluminum oxide, emery and flint.